Abstract: A method utilizes a funnel system and robotic end effector grippers to feed an unjacketed portion of a shielded cable through a sleeve. The funnel is designed with one or more thin extensions (hereinafter “prongs”) on which a sleeve is placed prior to a cable entering the funnel. Preferably two or more prongs are employed, although a single prong may be used if properly configured to both guide a cable and fit between the sleeve and cable. The prongs close off the uneven surface internal to a sleeve and provide a smooth surface for the cable to slide along and through the sleeve, preventing any damage to the exposed shielding. The sleeve is picked up and held on the prongs using a robotic end effector. If the sleeve is a solder sleeve, the robotic end effector has grippers designed to make contact with the portions of the solder sleeve that are between the insulating rings and the central solder ring.

Abstract: Thermal control system for aircraft main landing gear wheel wells and related methods are disclosed. An example thermal control system includes a conduit defining a fluid passageway between an inlet and an outlet. The inlet of the conduit positioned in fluid communication with a landing gear wheel well and the outlet of the conduit positioned in fluid communication with the atmosphere. The conduit generates a pressure differential through the fluid passageway between the inlet and the outlet to exhaust heat from the landing gear wheel well to the atmosphere.

Abstract: A method utilizes a funnel system and robotic end effector grippers to feed an unjacketed portion of a shielded cable through a sleeve. The funnel is designed with one or more thin extensions (hereinafter “prongs”) on which a sleeve is placed prior to a cable entering the funnel. Preferably two or more prongs are employed, although a single prong may be used if properly configured to both guide a cable and fit between the sleeve and cable. The prongs close off the uneven surface internal to a sleeve and provide a smooth surface for the cable to slide along and through the sleeve, preventing any damage to the exposed shielding. The sleeve is picked up and held on the prongs using a robotic end effector. If the sleeve is a solder sleeve, the robotic end effector has grippers designed to make contact with the portions of the solder sleeve that are between the insulating rings and the central solder ring.

Abstract: An automated system for processing an end of a cable. The system includes: a cable delivery system; a cable processing module; a pallet supported by the cable delivery system; a drive wheel rotatably coupled to the pallet; a motor operatively coupled for driving rotation of the drive wheel; and an idler wheel rotatably coupled to the pallet and forming a nip with the drive wheel. The cable processing module includes cable processing equipment and a computer system. The computer system is configured to: (a) cause the drive wheel to rotate in a cable pushing direction to cause a specified length of cable to be inserted into the cable processing equipment; (b) activate the cable processing equipment to operate on the cable end; and (c) cause the drive wheel to rotate in a cable pulling direction to cause the length of cable to be removed from the cable processing equipment.

Abstract: A system configured to position a tip of a cable. The system includes: a cable delivery system; a cable tip positioning module situated at a workstation in proximity to the cable delivery system; a pair of wheels operable to push a cable into the cable tip positioning module when a cable is in a nip between the wheels; an apparatus configured to hold the wheels; a motor operatively coupled to drive rotation of the wheels; and a proximity sensor configured to issue a cable present signal indicating the proximity of a conductor in the cable. The cable tip positioning module comprises a computer system configured to activate the motor to drive rotation of the wheels in a cable pulling direction in response to issuance of the cable present signal.

Abstract: Methods and apparatus for temporarily holding one end of a wire on a harness form board during automated transfer from one robot to another robot. The apparatus includes a wire holding device which is designed to facilitate the transfer of a wire end from a first end effector of a first robot to a second end effector of a second robot. The wire holding devices have different structures, but share the common feature that opening of the wire holding device (to enable wire insertion) involves applying a contact force which overcomes a spring force that urges the wire holding device to be closed. The end effectors are designed and their movements are controlled in a manner such that the moving end effector applies the contact force necessary to overcome the closure-inducing spring force being exerted.

Abstract: Systems and methods for designing and assembling form boards with attached wire routing devices for use in wire bundle assembly. The assembly method comprises: (a) establishing a coordinate system of a form board having a multiplicity of holes; (b) using a computer system to determine locations of form board devices of different types with reference to the coordinate system of the form board based on engineering data specifying a wire bundle configuration; and (c) fastening the form board devices of different types to respective holes of the form board having centers closest to respective locations determined in step (b). The form board devices may be inserted robotically or manually.

Abstract: Systems and methods for designing and assembling form boards with attached wire routing devices for use in wire bundle assembly. The assembly method comprises: (a) establishing a coordinate system of a form board having a multiplicity of holes; (b) using a computer system to determine locations of form board devices of different types with reference to the coordinate system of the form board based on engineering data specifying a wire bundle configuration; and (c) fastening the form board devices of different types to respective holes of the form board having centers closest to respective locations determined in step (b). The form board devices may be inserted robotically or manually.

Abstract: Methods and apparatus for robot motion control and wire dispensing during automated routing of wires onto harness form boards. The robot includes a manipulator arm and a wire-routing end effector mounted to a distal end of the manipulator arm. The wire-routing end effector is configured for dispensing and routing a wire along a path through form board devices mounted to a harness form board. The wire-routing end effector is moved along a planned path under the control of a robot controller. An end effector path is provided with a set of processes that enable rapid, even fully automatic, development of robot motion controls for routing wires on harness form boards. The system uses a measurement encoder on the end effector that is routing individual wires on a wire harness form board to learn the length of each wire and its length variation.

Abstract: Methods and apparatus for robot motion control and wire dispensing during automated routing of wires onto harness form boards. The robot includes a manipulator arm and a wire-routing end effector mounted to a distal end of the manipulator arm. The wire-routing end effector is configured for dispensing and routing a wire along a path through form board devices mounted to a harness form board. The wire-routing end effector is moved along a planned path under the control of a robot controller. An end effector path is provided with a set of processes that enable rapid, even fully automatic, development of robot motion controls for routing wires on harness form boards. The system uses a measurement encoder on the end effector that is routing individual wires on a wire harness form board to learn the length of each wire and its length variation.

Abstract: An apparatus for processing a cable including an insulating member, a shielding layer, and a conductor, the apparatus includes a frame forming a housing having an aperture configured to receive an end portion of the cable; a first gripping member disposed within the housing and being configured to grip the cable; and a second gripping member disposed within the housing and being configured to grip the cable; wherein the second gripping member is mounted within the housing so as to be movable relative to the first gripping member to effect fanning and cutting of a portion of the shielding layer.

Abstract: Semi-automated (with manual feeding) and fully automated (with automated feeding) solutions for using a vision system to evaluate shield trim quality on shielded cables. The vision system uses a multiplicity of cameras and a corresponding multiplicity of mirrors in order to achieve a 360-degree view of the cable segment to be inspected. Cables to be inspected are positioned in a repeatable location based on the strip length of the cable (where the edge of the cable jacket is located relative to the end of the cable). The processing system receives a live image feed from the camera system and then uses color and dimensional analysis of the acquired images to determine whether the shield trim meets quality control specifications or not.

Abstract: A bundle gripping tool employs a support ring concentric to a bundle axis and having a first open sector accessing a central aperture. A closure ring mounted on the support ring is concentric with and rotatable about the bundle axis and has a second open sector wherein rotation of the closure ring to an open position at least partially aligns the first and second open sectors exposing the central aperture. Rotation to a closed position misaligns the second open sector from the first open sector, covering the first open sector gating the central aperture. A plurality of snare cables is engaged between a first set of attachment points on the support ring and a second set of attachment points on the closure ring. The first set of attachment points and second set of attachment points are relatively positioned whereby each of said plurality of snare cables partially encircles the bundle axis in the closed position and exposes the bundle axis in the open position.

Abstract: A method of operating an automated machine is provided for inserting wires into grommet cavity locations of an electrical connector to compensate for manufacturing tolerances associated with the electrical connector. The method comprises inserting wires into grommet cavity locations of the electrical connector based upon a plug map having offset values to compensate for manufacturing tolerances associated with the electrical connector. The method may further comprise selecting from a plurality of pre-generated plug maps having offset values the closest matching pre-generated plug map for the electrical connector based upon offset values associated with each of the plurality of pre-generated plugs maps. The selected pre-generated plug map having offset values corresponds to the plug map used to insert wires into grommet cavity locations of the electrical connector.

Abstract: A system for processing an end of a cable. The system includes: a cable delivery system; a cable processing module; a pallet supported by the cable delivery system; a drive wheel rotatably coupled to the pallet; a motor operatively coupled for driving rotation of the drive wheel; and an idler wheel rotatably coupled to the pallet and forming a nip with the drive wheel. The cable processing module includes cable processing equipment configured to perform an operation on an end of a cable and a computer system. The computer system is configured to: (a) cause the drive wheel to rotate in a cable pushing direction to cause a specified length of cable to be inserted into the cable processing equipment; (b) activate the cable processing equipment to perform an operation on the inserted end of the cable; and (c) cause the drive wheel to rotate in a cable pulling direction to cause the specified length of cable to be removed from the cable processing equipment.

Abstract: A method utilizes a funnel system and robotic end effector grippers to feed an unjacketed portion of a shielded cable through a sleeve. The funnel is designed with one or more thin extensions (hereinafter “prongs”) on which a sleeve is placed prior to a cable entering the funnel. Preferably two or more prongs are employed, although a single prong may be used if properly configured to both guide a cable and fit between the sleeve and cable. The prongs close off the uneven surface internal to a sleeve and provide a smooth surface for the cable to slide along and through the sleeve, preventing any damage to the exposed shielding. The sleeve is picked up and held on the prongs using a robotic end effector. If the sleeve is a solder sleeve, the robotic end effector has grippers designed to make contact with the portions of the solder sleeve that are between the insulating rings and the central solder ring.

Abstract: Semi-automated (with manual feeding) and fully automated (with automated feeding) solutions for using a vision system to evaluate shield trim quality on shielded cables. The vision system uses a multiplicity of cameras and a corresponding multiplicity of mirrors in order to achieve a 360-degree view of the cable segment to be inspected. Cables to be inspected are positioned in a repeatable location based on the strip length of the cable (where the edge of the cable jacket is located relative to the end of the cable). The processing system receives a live image feed from the camera system and then uses color and dimensional analysis of the acquired images to determine whether the shield trim meets quality control specifications or not.

Abstract: A shield trim is performed by tearing bunched shield strands circumferentially along a circular edge. The apparatus includes a pair of aligned metal plates that have been drilled through multiple times such that holes of varying diameters pass may be passed through both plates. A cable gripper on the entry side of the device clamps the cable in place. A shield gripper on the rear side of the device closes over the exposed shielding of the cable, and the two plates are pushed together. The shield gripper travels with the rear plate, pushing the shield over the wires and causing the shield to bunch between the two plates. With the two plates pushed together, both grippers open and the cable is pulled free from the device. This pull forces a stress concentration on the shield strands as they are pulled and subsequently torn across the sharp edge of the hole, producing a uniformly trimmed shield.

Abstract: An automated system for processing an end of a cable. The system includes: a cable delivery system; a cable processing module; a pallet supported by the cable delivery system; a drive wheel rotatably coupled to the pallet; a motor operatively coupled for driving rotation of the drive wheel; and an idler wheel rotatably coupled to the pallet and forming a nip with the drive wheel. The cable processing module includes cable processing equipment configured to perform an operation on an end of a cable and a computer system. The computer system is configured to: (a) cause the drive wheel to rotate in a cable pushing direction to cause a specified length of cable to be inserted into the cable processing equipment; (b) activate the cable processing equipment to perform an operation on the inserted end of the cable; and (c) cause the drive wheel to rotate in a cable pulling direction to cause the specified length of cable to be removed from the cable processing equipment.

Abstract: A method 500 of operating an automated machine 100 is provided for inserting wires into grommet cavity locations 110 of an electrical connector 112 to compensate for manufacturing tolerances associated with the electrical connector. The method comprises inserting wires into grommet cavity locations of the electrical connector based upon a plug map 300 having offset values to compensate for manufacturing tolerances associated with the electrical connector. The method may further comprise selecting from a plurality of pre-generated plug maps having offset values the closest matching pre-generated plug map for the electrical connector based upon offset values associated with each of the plurality of pre-generated plugs maps. The selected pre-generated plug map having offset values corresponds to the plug map used to insert wires into grommet cavity locations of the electrical connector.